Project #1: Using Augmented Reality (AR) and Digital Twin Technology to Empower Workers
Maple Leaf Foods is committed to leveraging advanced automation and digital technologies which has not only enhanced its production efficiency but also solidified its position as an industry leader in sustainable food processing. The company's collaboration with RidgeTech Automation, Rockwell Automation, Harpak-ULMA Packaging, and PTC has demonstrated the transformative power of technology in tackling industry challenges, from worker training to operational optimization. As they continue to innovate with cutting-edge solutions like augmented reality and digital twins, Maple Leaf Foods is paving the way for the future of food processing.
Across three locations:
- Implement the latest in automation and digital transformation technology to improve OEE
- Empower workers
- Gain a competitive advantage in highly regulated and competitive industries
Guelph Manufacturing Plant
- Vuforia Augmented Reality software
- Harpak-ULMA machine-based AR experiences
London Poultry Processing Plant
- FactoryTalk® View SE
- FactoryTalk® AssetCentre
- ControlLogix® 5580
- CompactLogix® 5380
- PowerFlex® Variable Frequency Drives
- POINT I/O™ and POINT Guard I/O™ modules
- ThinManager®
- Emulate3D®
Brampton Manufacturing Plant
Guelph Manufacturing Plant
- Improved operator efficiency and training
- Improved OEE
London Poultry Processing Plant
- Enhanced product flow
- Reduced operating costs
Brampton Manufacturing Plant
- Achieved a better understanding of throughput
Price pressure and competition for skilled workers is fierce in the protein industry. To be successful, food producers like Maple Leaf Foods must find better ways to capture more value from the equipment on their plant floors—and attract, train, and retain workers. Paired with the tight talent landscape, the global demand for food continues to grow. Food manufacturers are under increased pressure to adopt automation and carbon neutral methods to improve operational efficiency, seamlessly integrate equipment, gain visibility across their systems, and secure IT and OT networks.
As the world's first carbon-neutral food company, Maple Leaf Foods has embraced automation and digital transformation at every level to drive efficiency and quality. The company has formed strategic partnerships and launched innovative programs at multiple facilities. These programs allow facilities to try new applications for automation and digital transformation technology – gaining a competitive edge by using the latest technologies to improve quality and productivity.
With a strong reputation for quality and innovation through brands like Maple Leaf, Schneiders, and Greenfield Natural Meat Co., the food producer leads the industry by integrating cutting-edge technologies that enhance production and sustainability.
Challenge
Leadership at Maple Leaf Foods’ Guelph Manufacturing Plant identified a need to improve overall equipment effectiveness (OEE) and worker training. Maple Leaf Foods, along with Rockwell Automation and PartnerNetwork™ members Harpak-ULMA Packaging and PTC, set out to develop an AR-based training program using Vuforia® Expert Capture.
Solution
Harpak-ULMA deployed its embedded OEE Application, which automatically calculates, monitors, and reports packaging line performance in real time. Next, Harpak-ULMA deployed the entire library of PTC AR applications and created its own machine-based AR experiences.
Most AR user experiences leverage the machine’s digital twin, a dynamic model that virtually represents the physical machine. The pilot project quickly demonstrated the value of AR in a packaging line. For example, the OEE application delivers self-diagnosing machine reports that identify machine downtime and high-priority action items by shift. Using remote connectivity, the Harpak-ULMA team monitors these reports daily, identifies any high-frequency stoppages – and then builds step-by-step AR-based remediation routines that operators can access in real time.
Result
AR-based training is underway, and the company is in the process of evaluating the benefits. They anticipate that the interactive, visually intensive training will help minimize language barriers, decrease worker error – and reduce training cycles in an environment that often experiences high staff turnover.
Project #2: Digital Transformation in the Largest Poultry Processing Plant in the World
Challenge
Maple Leaf Foods needed to reduce operator training, be nimbler with staffing, and be positioned to respond quickly and effectively to events that happen at any facility. A core part of their strategy to build resiliency within their manufacturing facilities is to coordinate with strategic partners and suppliers to implement a standardized system for controlling, visualizing, and managing operations. This system is used across manufacturing facilities.
Due to its established relationship, Maple Leaf Foods entrusted RidgeTech Automation, a System Integrator in the Rockwell Automation PartnerNetwork™ to architect, manage, and implement this standard system.
Solution
Maple Leaf Foods and RidgeTech Automation worked alongside Rockwell Automation to design a common controls architecture using ControlLogix® 5580, CompactLogix® 5380, alongside PowerFlex® Variable Frequency Drives and POINT I/O™ and POINT Guard I/O™ modules. A SCADA system for process control and monitoring was also built using FactoryTalk® View SE. This standard system is now used for any new build.
In 2021, Maple Leaf Foods began construction in London, Ontario to build the largest, most technically advanced poultry processing plant in the world. Inside the 660,000 square foot facility would be more than 4,000 pieces of equipment. The project was huge: 175 PLCs and over 1,500 VFDs were implemented.
Result
Once the build phase was complete, Maple Leaf Foods looked for ways to optimize production. One area of focus was the grading and packaging area of the plant. In this area, complex equipment sorts various cuts of poultry and then sends them through a tiered network of highway conveyors. To minimize product waste, Maple Leaf Foods wanted to achieve the highest level of sorting and conveying accuracy.
RidgeTech used Emulate3D™ digital twin software from Rockwell Automation to create a digital twin of the process. Then, they modeled traffic flow and identified bottlenecks and underutilized areas within the conveyance highway. Machine learning technology was applied to the simulation to find the optimal material flow. The entire study was completed digitally while production continued. The result was a system design that achieved material handling accuracy of more than 99%.
Published April 23, 2025
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